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US-12626856-B2 - Reactor, method for manufacturing reactor, and reactor coil covering

US12626856B2US 12626856 B2US12626856 B2US 12626856B2US-12626856-B2

Abstract

There are provided a reactor, a reactor coil covering, and a method for manufacturing a reactor, which are capable of preventing peeling off of an insulation coat with which an outer peripheral surface of a winding is covered. A reactor includes a core, a coil disposed on an outer periphery of the core, and a resin mold portion partially covering and integrating the core and the coil. A winding of the coil has an outer peripheral surface covered with an insulation coat. At least one part of a surface of the coil is covered with a protective membrane to cover a boundary between adjacent turns of the coil.

Inventors

  • Yusuke HORINO

Assignees

  • TOKAI KOGYO CO., LTD.

Dates

Publication Date
20260512
Application Date
20210625
Priority Date
20200821

Claims (9)

  1. 1 . A reactor comprising: a core; a coil disposed on an outer periphery of the core; and a resin mold portion partially covering and integrating the core and the coil, wherein a winding of the coil has an outer peripheral surface covered with an insulation coat, and at least one part of a surface of the coil is covered with a protective membrane to cover a boundary between adjacent turns of the coil, and the protective membrane has a plurality of perforations in order to later expose the coil between the perforations.
  2. 2 . The reactor according to claim 1 , wherein the protective membrane is a film.
  3. 3 . The reactor according to claim 1 , wherein at least one part of a region which is not covered with the resin mold portion on the surface of the coil is not covered with the protective membrane.
  4. 4 . A reactor coil covering comprising: a coil disposed on an outer periphery of a core, wherein a winding of the coil has an outer peripheral surface covered with an insulation coat, at least one part of a surface of the coil is covered with a protective membrane to cover a boundary between adjacent turns of the coil, and the protective membrane has a plurality of perforations in order to later expose the coil between the perforations.
  5. 5 . A method for manufacturing a reactor, the reactor including a core, a coil disposed on an outer periphery of the core, and a resin mold portion partially covering and integrating the core and the coil, a winding of the coil having an outer peripheral surface covered with an insulation coat, the method comprising: a coil covering preparing operation of providing a coil covering formed by covering at least one part of a surface of the coil with a protective membrane to cover a boundary between adjacent turns of the coil; a coil assembly preparing operation of providing a coil assembly formed by assembling the core and the coil covering; a resin mold portion molding operation of setting the coil assembly in a forming mold and then performing an injection molding to mold the resin mold portion; and a peeling operation of peeling off at least one part of the protective membrane corresponding to a portion which is not covered with the resin mold portion in the coil covering, after the resin mold portion molding operation.
  6. 6 . The method for manufacturing a reactor according to claim 5 , wherein after the coil covering preparing operation and before the coil assembly preparing operation, a resin portion molding operation of molding a resin portion configuring a part of the resin mold portion is performed by performing the injection molding after setting the coil covering in the forming mold.
  7. 7 . The method for manufacturing a reactor according to claim 5 , wherein the coil covering preparing operation includes covering the at least one part of the surface of the coil with a film that is the protective membrane.
  8. 8 . The method for manufacturing a reactor according to claim 7 , wherein the coil covering preparing operation includes covering at least one portion against which the forming mold abuts with the film on the surface of the coil.
  9. 9 . The method for manufacturing a reactor according to claim 5 , wherein the protective membrane is a film to which a perforation is formed, and the peeling operation includes cutting the protective membrane along the perforation.

Description

TECHNICAL FIELD The present invention relates to a reactor used as a component of a converter or the like, a method for manufacturing the reactor, and a reactor coil covering. BACKGROUND ART In the related art, a hybrid vehicle or an electric vehicle is equipped with a converter for boosting a battery voltage, and the converter includes a part such as a reactor. The reactor is manufactured, for example, by inserting a coil assembly into a mold, and filling the mold with a molten resin material and injection molding the molten resin material, the coil assembly including a core and a coil formed by winding windings around an outer periphery of the core (for example, see Patent Literature 1). CITATION LIST Patent Literature Patent Literature 1: JP2010-074150A (see paragraphs 0049, 0071 to 0077, FIGS. 2 and 4, etc.) DISCLOSURE OF INVENTION Technical Problem However, in the related art described in Patent Literature 1, a foreign substance (for example, sintered metal particles or metal chips of the core) may be caught in a gap between the windings forming the coil. In addition, when the coil with the core inserted therein is disposed in the mold or when the mold is closed, a surface of the coil may come into contact with the mold. Then, in these cases, the windings are likely to be damaged, and an insulation coat (enamel coat) covering the windings may peel off. As a result, a short circuit may occur between the windings, resulting in heat generation. The present invention is made in view of the above-mentioned problems, and an object thereof is to provide a reactor capable of preventing peeling off of an insulation coat with which an outer peripheral surface of a winding is covered, a method for manufacturing the reactor, and a reactor coil covering. Solution to Problem In order to solve the above-mentioned problems, a gist of an invention according to a solution 1 is a reactor including a core; a coil disposed on an outer periphery of the core; and a resin mold portion partially covering and integrating the core and the coil. A winding of the coil has an outer peripheral surface covered with an insulation coat, and at least one part of a surface of the coil is covered with a protective membrane to cover a boundary between adjacent turns of the coil. Therefore, according to the invention according to the solution 1, since the at least a part of the surface of the coil is covered with the protective membrane so as to cover the boundary between the adjacent turns of the coil, it is possible to prevent a foreign substance (for example, sintered metal particles or metal chips of the core) from being caught in a gap between the adjacent turns. In addition, it is also possible to prevent other members (for example, a forming mold for molding the resin mold portion) from coming into contact with the surface of the coil. As a result, since the coil is less likely to be damaged, it is possible to prevent peeling off of the insulation coat with which the outer peripheral surface of the winding is covered. A gist of an invention according to a solution 2 is that in the solution 1, the protective membrane is a film. Therefore, according to the invention according to the solution 2, by covering the surface of the coil with the film, the gap between the adjacent turns of the coil can be closed with the film, and thus it is possible to prevent a foreign substance from entering the gap. A gist of an invention according to a solution 3 is that in the solution 1 or 2, at least one part of a region which is not covered with the resin mold portion on the surface of the coil is not covered with the protective membrane. Therefore, according to the invention according to the solution 3, since heat is released from a region on the surface of the coil which is not covered with the resin mold portion, is not covered with the protective membrane, and is exposed to the outside, a predetermined heat dissipation property can be ensured. A gist of an invention according to a solution 4 is a reactor coil covering including a coil disposed on an outer periphery of a core. A winding of the coil has an outer peripheral surface covered with an insulation coat, and at least one part of a surface of the coil is covered with a protective membrane to cover a boundary between adjacent turns of the coil. Therefore, according to the invention according to the solution 4, since the at least a part of the surface of the coil is covered with the protective membrane so as to cover the boundary between the adjacent turns of the coil, it is possible to prevent a foreign substance from being caught in a gap between the adjacent turns. In addition, it is also possible to prevent other members from coming into contact with the surface of the coil. As a result, since the coil is less likely to be damaged, it is possible to prevent peeling off of the insulation coat with which the outer peripheral surface of the winding is covered. A gist of an invention according